Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
  • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
  • B32B37/24—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
  • B29C44/34—Auxiliary operations
  • B29C44/56—After-treatment of articles, e.g. for altering the shape
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B60—VEHICLES IN GENERAL
  • B60N—SEATS SPECIALLY ADAPTED FOR VEHICLES; VEHICLE PASSENGER ACCOMMODATION NOT OTHERWISE PROVIDED FOR
  • B60N3/00—Arrangements or adaptations of other passenger fittings, not otherwise provided for
  • B60N3/04—Arrangements or adaptations of other passenger fittings, not otherwise provided for of floor mats or carpets
  • B60N3/048—Arrangements or adaptations of other passenger fittings, not otherwise provided for of floor mats or carpets characterised by their structure
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
  • B29K2105/26—Scrap or recycled material
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2305/00—Condition, form or state of the layers or laminate
  • B32B2305/70—Scrap or recycled material
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B60—VEHICLES IN GENERAL
  • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
  • B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
  • B60R13/08—Insulating elements, e.g. for sound insulation
  • B60R13/0815—Acoustic or thermal insulation of passenger compartments
  • B60R13/083—Acoustic or thermal insulation of passenger compartments for fire walls or floors
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
  • Y10T156/10—Methods of surface bonding and/or assembly therefor
  • Y10T156/1002—Methods of surface bonding and/or assembly therefor with permanent bending or reshaping or surface deformation of self sustaining lamina

Definitions

• the invention relates to a method for producing textile top floors in motor vehicles.
• Textile top floors in motor vehicles are known per se. These are usually produced by first forming a textile floor covering in a die shape of the floor panel of the motor vehicle. As a result of the transmission tunnel or elevations or depressions located on the base plates, height differences of a few millimeters to several centimeters occur.
• velor or needle felt floor coverings are usually used.
• the floor coverings of high-quality vehicles are provided with a so-called heavy foil. This is, for example, an EPDM film containing up to 70% by weight of filler.
• the laminate of back-coated carpet and heavy film thus obtained is usually subjected to the deformation.
• an absorption foam backing is placed on the top with the aid of the back-spraying process called laminate applied.
• laminate applied the use of a filled two-component polyurethane foam (low expansion foam) is preferred in the prior art, which is injected into the tool. This polyurethane foam is acoustically effective in combination with the heavy film.
• DE 40 15 413 A1 discloses the production of a molded part of any shape and size from recycled materials.
• the molded part consists of foams or foam wastes which are torn into flake form and intimately mixed with a one-component binder based on corn and / or wheat starch. Bonding the molded parts to other objects is not described.
• DE 34 30 775 C2 relates to a carpet part, a process for its production and its use.
• a carpet part for sound insulation, in particular in motor vehicles, is then provided from a carpet and a heavy layer arranged underneath it or with the carpet forming a unitary whole and a synthetic lower layer arranged underneath, the lower layer consisting of a combination of foam or nonwoven layers with different layers Resistance to interference exists.
• the layer sequence consists for example of carpet, heavy layer, foam layer with a relatively high Flow resistance and a foam layer with a relatively low flow resistance.
• the transmission tunnel 11 and a cable shaft 12 protrude from the otherwise flat die shape. While the cable duct 12 is not visible from the top of the doctored layer 2 made of foam flakes and self-curing binder, the transmission tunnel 11 is enclosed by the mixture with a constant layer thickness.
• FIG. 2 shows the complete structure of the textile top floors according to the invention in motor vehicles in the form of a die of the floor panel 1.
• the heavy film 3 is located on the layer of foam flakes and self-curing binder 2, which in turn is connected to the textile top floor 4.
• the textile floor covering 4 provided with a heavy film 3 by pressing the textile floor covering 4 provided with a heavy film 3 and heating the laminate, it is possible to achieve a good adhesion of the absorption foam 2 to the heavy film 3.
• the uniform density of the absorption foam 2 over the entire volume of the foam causes a uniform sound absorption quality.
• the method according to the invention thus enables the reuse of foam flakes to a large extent, which are obtained, for example, in the production of objects other than waste materials.
• a mixture of 70 to 99% by volume of foam flakes and 1 to 30% by volume of binder is crocheted into a female form of the floor panel 1 of the motor vehicle.
• a further preferred embodiment of the present invention consists in scraping up a mixture of 75 to 90% by volume of foam flakes and 10 to 25% by volume of binder.
• the size of the foam flakes is of less importance, but it should not exceed the minimum layer thickness of the absorption foam, for example above the cable duct 12, since otherwise the surface would not be sufficiently smooth Application of the textile floor covering 4 is created. Accordingly, it is particularly preferred to use foam flakes in a size of 1 to 30 mm. Since the thickness of the absorption foam 2 for the production of textile top floors 4 in motor vehicles is usually approximately 2 to 100 mm, in particular 5 to 80 mm, the size of the foam flakes chosen in this way ensures that the restoring forces of the foam flakes do not deteriorate the surface quality of the absorption foam 2 lead.
• the selection of the self-curing binder is practically not subject to any restrictions, as long as the binder is suitable for connecting the foam flakes used sufficiently firmly and having sufficient elasticity to be acoustically effective. In addition, sufficient wetting of the foam flakes is required to create a firm bond. A good connection with the heavy foil 3 must also be possible.
• a preferred embodiment of the present invention is that a phenolic resin, a one-component polyurethane or a latex emulsion, optionally filled with polyolefin fibers, for example polypropylene fibers, is used as the binder.
• the binder activities can be activated, for example by the action of temperature, water vapor and / or pressure.
• hardening of the optionally thermoplastic elastic binder occurs, which leads to an acoustically effective absorption foam 2 which has approximately the same density over the entire volume.
• the sound absorption properties are thus approximately the same over the entire volume.
• the absorption foam 2, on the one hand, and the heavy film 3, on the other hand are bonded by the self-hardening of the binder without an intermediate adhesive layer.
• the optionally preformed laminate of heavy film 3 and textile floor covering 4 is applied to the absorption foam 2 which has not yet cured and the binder is cured by appropriate activation, for example an increase in temperature, and is thus connected to the heavy film 3.
• the binders can be pure thermoplastics, thermosets or a suitable combination of both.
• a heavy-duty EPDM heavy-duty film 3 filled with up to 70% by weight of filler can be used, for example.
• a back-coated velor or needle felt known in the prior art can be used as a textile floor covering 4 in the sense of the present invention.
• the laminate of back-coated velor or needle felt covering and heavy film 3 is preferably preformed accordingly before being applied to the absorption foam. In the same way, however, it is possible to deform the textile covering when connecting it to the absorption foam 2.

Landscapes

• Engineering & Computer Science (AREA)
• Transportation (AREA)
• Mechanical Engineering (AREA)
• Laminated Bodies (AREA)
• Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
• Carpets (AREA)

Priority Applications (2)

Applications Claiming Priority (2)

Publications (1)

Family

ID=6462502

Family Applications (1)

Country Status (6)

Cited By (3)

Families Citing this family (9)

Citations (5)

Family Cites Families (15)

• 1992
  • 1992-07-04 DE DE4222023A patent/DE4222023A1/de not_active Withdrawn
• 1993
  • 1993-07-01 CZ CZ19958A patent/CZ286078B6/cs not_active IP Right Cessation
  • 1993-07-01 EP EP93915764A patent/EP0651700B1/de not_active Expired - Lifetime
  • 1993-07-01 DE DE59305653T patent/DE59305653D1/de not_active Expired - Fee Related
  • 1993-07-01 WO PCT/EP1993/001699 patent/WO1994001278A1/de not_active Ceased
  • 1993-07-01 ES ES93915764T patent/ES2099959T3/es not_active Expired - Lifetime
• 1997
  • 1997-09-29 US US08/939,201 patent/US5935677A/en not_active Expired - Fee Related

Patent Citations (5)

Non-Patent Citations (2)

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